Contents 1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 User Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Congratulations About This Manual Toll free: 1-800-626-2811. Customer Service hours: Monday - Friday 8 AM- 5 PM Central Standard Time (CST) This manual contains important information regarding safety, assembly, use, and maintenance of the scooter but is not intended to be a complete or comprehensive manual covering all aspects concerning scooter ownership.
Helmets Save Lives! Correct Fitting Make sure your helmet covers your forehead • ALWAYS WEAR A PROPERLY FITTED HELMET WHEN RIDING YOUR SCOOTER • DO NOT RIDE AT NIGHT • AVOID RIDING IN WET CONDITIONS Incorrect Fitting Forehead is exposed and vulnerable to serious injury 3
1 Safety ❶ Safety SAFETY SIGNAL WORDS USER RESPONSIBILITY The following safety signal words indicate a safety message. The symbol alerts you to potential hazards. Failure to follow the warning may result in damage to property, injury, or death. All persons assembling, using, and maintaining the scooter must read and understand the safety warnings and operating instructions in this manual before using the scooter.
Safety 1 PERSONAL SAFETY WARNING! Riding a scooter without protective gear, clothing, or a helmet may result in serious injury or death. Always wear protective gear, clothing, and helmet when riding the scooter. Ensure protective gear does not interfere with steering, braking, and pushing. Protective Gear and Clothing Always wear: Figure 1.
1 Safety Helmet Use Important! Many states have passed helmet laws regarding children. Make sure you know your states helmet laws. It is your job to enforce these rules with your children. Even if your state does not have a children’s helmet law, it is recommended that everyone wear a helmet. It is strongly advised that a properly fitting, ASTM or SNELL approved, bicycle helmet be worn at all times when riding your scooter. The correct helmet should: Figure 1.
Safety 1 RIDING SAFETY WARNING! Riding the scooter in unsafe conditions (i.e.: at night), in an unsafe manner, or disregarding traffic laws may result in an unexpected movement, loss of control, and serious injury or death. General Safety • Familiarize yourself with all the scooter’s features before riding. Practice braking. • Always ride defensively in a predictable, straight line. Never ride against traffic. • Expect the unexpected (e.g., opening car doors or cars backing out of concealed driveways).
1 Safety Night Riding Safe Riding Rules for Children • Important! Riding a scooter at night is not recommended. Check your local laws regarding night riding. • Many states require that children wear a helmet while riding. Always wear a properly fitted helmet. • Wear reflective and light colored clothing. Wear reflective clothing and use safety lights for increased visibility. • Do not play in driveways or the road. • Ride at night only if necessary.
Safety 1 BEFORE YOU RIDE SAFETY CHECKLIST Before every ride, it is important to carry out the following safety checks. Do not ride a scooter that is not in proper working condition! Replace any worn or broken parts as needed. Accessories □ □ □ The frame and fork are not bent or broken. Steering □ The handlebar and post are correctly adjusted and tightened, and allow proper steering. □ All other fittings on the scooter are properly and securely fastened, and functioning.
❷ Parts Identification Expo Scooter Get to know the parts of your scooter. This will help with assembly, maintenance, and troubleshooting. Models vary in color and style.
Parts Identification 2 1 2 9 3 8 4 5 6 7 20C 22C 20B 20A 10 22A 20 11 12 22B 19 18 17 16 15 14 23 24 25 26 22 21 13 11
3 Assembly ❸ Assembly WARNING! • Improper assembly of this product may result in serious injury or death. Always follow the instructions in this manual and check critical components (e.g.: wheels, brakes, tires) before each use. • We recommend that you consult a bicycle mechanic if you have doubts or concerns as to your experience or ability to properly assembly, repair, or maintain your scooter.
Assembly 3 GETTING STARTED ❶ Open the carton from the top and remove the scooter. Figure 3.2 Handlebar assembly ❷ Remove the straps and protective packaging from the scooter. Important! Do not discard packing materials until assembly is complete to ensure that no required parts are accidentally discarded. ❸ Inspect the scooter and all accessories and parts for possible shortages. It is recommended that the threads and all moving parts in the parts package be lubricated prior to installation.
3 Assembly ATTACH THE HANDLEBAR WARNING! • Improper attachment of the handlebar may result in damage to the stem post, steering tube and result in lose of control, serious injury or death. Ensure the minimum insertion marks on the stem post are not visible above the top of the headset. • Failure to properly tighten handlebar components may result in lose of control, serious injury or death. Always check the handlebar cannot move and is secured to the frame before riding the scooter.
Assembly 3 ATTACH THE FRONT BRAKE CABLE WARNING! Failure to properly set the brakes may result in the inability to stop the scooter movement and cause serious injury or death. Be sure the brakes are functioning properly before using the scooter. Cable adjustment Cable nut slot barrel slot 1 2 Brake cable slot Brake lever ❶ Rotate the cable adjustment barrel and cable nut until the slots are aligned with the slot on the brake lever body. Figure 3.4 Figure 3.
3 Assembly CABLE DETANGLER Some scooters are equipped with a cable detangler for the rear brake. Follow these steps to attach the upper cable to the rear brake lever. Figure 3.7 ❶ Loop the upper cables through the opening on the handlebar. Note: One of the upper cable casings is shorter than the other. The shorter side should be on the right. This is the shorter distance between the brake lever and the upper detangler plate.
Assembly 3 Front View of Scooter Cable adjuster Cable splitter Front brake cable Single cable casing Rear brake lever Upper cable (short casing) Cable adjusting barrel 1 Front brake lever Upper cable (long casing) 4 1 mm (1/32") 2 3 1 mm (1/32") 4 Upper cable adjusting barrels Locknut Upper plate Lower plate Bearing unit Locknut Lower cable adjusting barrels Lower cable Lower cable Important! The gap between the plates and bearing unit should be a minimum 1 mm (1/32”) when the brake is eng
3 Assembly ATTACH THE FRONT WHEEL ❶ Loosen the axle nuts on the front wheel. If there is a washer inside of the axle nut, it belongs outside of the fork dropouts. 3 ❷ Position the front wheel between the front fork legs with the axle resting inside the fork drop out. Figure 3.8 Important! Be sure the wheel is as centered as possible between the fork legs. ❸ Place the clip retaining washer on the axle and slide it up against the fork drop out.
Assembly 3 ATTACH THE REAR WHEEL ❶ Loosen the axle nuts on the rear wheel. If there is a washer inside of the axle nut, it belongs outside of the fork dropouts. 3 ❷ Position the rear wheel between the rear fork legs with the axle resting inside the fork drop out. Figure 3.10 Clip retaining washer inserted into dropout hole Figure 3.11 Important! Be sure the wheel is as centered as possible between the fork legs. ❸ Place the clip retaining washer on the axle and slide it up against the fork drop out.
3 Assembly ATTACH THE PEGS Important! Periodically check to make sure pegs are tight. Some models may come equipped with 2 or 4 pegs. Peg 3 To install pegs: ❶ Do not loosen or remove axle nuts. 2 ❷ Check to make sure axle nuts are properly tightened before installing pegs. Figure 3.12 3 ❸ Thread the pegs on the axle over the axle nut. ❹ Insert a screwdriver or similar tool through the peg holes and tighten by turning the peg with the tool. Figure 3.13 Clip retaining washer Axle nut Peg Figure 3.
Adjustments 4 ❹ Adjustments After your scooter is assembled you will need to make adjustments. If you need replacement parts or have questions pertaining to the assembly of your scooter, call the service line direct at: 1-800-626-2811. Monday - Friday 8:00 am to 5:00 pm Central Standard Time (CST). Note: You will need your model number and date code located on the service sticker.
4 Adjustments ADJUSTING THE BRAKES Adjusting the Side-pull Caliper Brakes Brake cable at brake lever 4 ❶ If the brake cable is disconnected at the caliper, thread the brake wire through the adjustment barrel. Figure 4.2 3 Brake wire Figure 4.3 ❷ Using a 10 mm open end wrench, loosen the cable anchor bolt until you can see a gap large enough for the cable wire. 2 ❸ Thread the cable wire through the gap. By hand, screw the cable anchor bolt snug enough to hold the cable wire.
Adjustments 4 Adjusting the Brake Pads Center the Brake Pads Important! Before riding the scooter it is important to check the brakes. If you squeeze the brake lever and one brake arm moves more than the other, (or not at all), the brake is not centered. You will need to fine tune the brake pads. Multiple adjustments may be necessary to center the brake pads, correctly set the brake pressure, and set the gap between the brake pad and rim.
4 Adjustments ❷ If the gap between the brake pad and wheel is uneven, adjust the position of the brake pad. Figure 4.6 • Loosen the nut on the back of the brake. • Squeeze the brake and hold the brake lever closed, while re-tightening the lock nut on the back of the brake. Note: Watch the brake, if it begins to shift or rotate, then release the brake lever, and use your hand to rotate the brake caliper back until both sides of the brake move equally.
Adjustments 4 Check the Brakes ❶ After adjusting the brake, squeeze the brake lever as hard as you can several times and re-inspect the brake pads, centering and brake lever travel. If the brake pads are no longer square to the rim, repeat brake pad adjustments. Figure 4.8 ❷ Be sure that brake pads return to a centered position by spinning the wheel and listening for the brake pad rubbing the rim on either side. Re-adjust as needed.
4 Adjustments ADJUSTING THE HANDLEBAR WARNING! • Improper adjustment of the handlebar may result in damage to the stem post, steering tube and result in lose of control, serious injury or death. Ensure the minimum insertion marks on the stem post are not visible above the top of the headset. • Failure to properly tighten handlebar components may result in lose of control, serious injury or death. Always check the handlebar cannot move and is secured to the frame before riding the bicycle.
Adjustments 4 Adjusting the Handlebar Alignment ❶ Using a 14 mm open-end wrench loosen the stem binder bolt. Figure 4.11 5 ❷ Move the handlebar left or right until it is aligned with the front wheel. ❸ Tighten the stem binder bolt. Check the handlebar binder bolts to be sure they are properly tightened and the handlebar is clamped in place. Adjusting the Handlebar Angle ❹ Loosen all of the handlebar binder bolts to allow the handlebar to move.
5 Use ❺ Use HAND OPERATED BRAKES WARNING! Failure to follow all local and state regulations and laws pertaining to scooter use as well as the safety warnings in this manual may result in serious injury or death. Always follow all local and state regulations and laws pertaining to scooter use, follow the safety warnings in this manual and use common sense when riding the scooter. Always conduct a pre-ride check of the scooter condition before riding.
Use 5 SECURITY You just bought a new scooter! Don’t lose it. It is advisable that the following steps be taken to prepare for and help prevent possible theft: • Invest in a bicycle lock that will resist hacksaws and bolt cutters. • Always lock your scooter to an immovable object if it is left unattended. Figure 5.2 Figure 5.
6 Maintenance ❻ Maintenance WARNING! • Failure to conduct maintenance on the scooter may result in malfunction of a critical part and serious injury or death. Proper maintenance is critical to the performance and safe operation of the scooter. • The recommended intervals and need for lubrication and maintenance may vary depending on conditions the scooter is exposed to. Always inspect the scooter and conduct necessary maintenance before each use of the scooter.
Maintenance 6 LUBRICATION SCHEDULE Component Lubricant Method Weekly Brake calipers Oil Three drops from oil can Brake levers Oil Two drops from oil can Brake cables Lithium based grease Remove cable from casing. Grease entire length. Wipe off excess lubrication from other surfaces.
6 Maintenance PARTS MAINTENANCE Brakes Frequency: Inspect and maintain before each use Inspect Action Maintenance Levers Check the levers are securely fastened to the handlebar. Position the levers to fit the rider’s grip and screw tight to handlebar. Pads Check pad position, gap and pressure. See Section 4: Adjusting the Brakes Cables Check the outer casing for kinks, stretched coils and damage. Check cables for kinks, rust, broken strands or frayed ends.
Maintenance 6 Tires Frequency: Inspect and maintain at least each use. Inspect Tire Inflation Action Maintenance Check tire pressure. Inflate tire to the pressure indicated on the tire sidewall. See “Inflating a Tire Tube” for more detail. If the tire is flat see “Fixing a Flat Tire” for more detail. Check the bead is properly seated while inflating or refitting the tire. Reduce air pressure in the tube and re-seat the bead. Spin wheel and check rotation / alignment is smooth and even.
6 Maintenance HUB BEARINGS Hub bearings require special thin wrenches called cone wrenches. If you do not own these tools, do not attempt hub bearing adjustments. Have a qualified bicycle mechanic perform the adjustment if you have any doubts. ❶ Check to make sure neither locknut is loose. ❷ To adjust, remove wheel from scooter and loosen the locknut on one side of the hub while holding the bearing cone on the same side with a cone wrench. ❸ Rotate the adjusting cone as needed to eliminate free play.
Maintenance 6 REPAIRING A FLAT TIRE WARNING! An unseated tire can rupture unexpectedly and cause serious injury or death. Be sure the tire is properly seated when inflating the tube. Follow these steps to fix a flat tire: ❿ Start at the valve stem and install the first bead onto the rim. Repeat for the second bead. ⓫ Slowly inflate the tire, checking the tire is seated properly and not pinched as the tire is inflated. ⓬ Inflate to recommended pressure (see tire sidewall).
6 Maintenance TROUBLESHOOTING GUIDE Problem Possible Cause Remedy Brakes not working effectively • • • • • Brake pads worn down Brake pads/rim greasy, wet or dirty Brake cables are binding/stretched/damaged Brake levers are binding Brakes out of adjustment • • • • • Replace brake pads Clean pads and rim Clean/adjust/replace cables Adjust brake levers Center brakes When applying the brakes they squeal/ squeak • • • • Brake pads worn down Brake pads toe-in incorrect Brake pads/rim dirty or wet Brak
Maintenance 6 Problem Steering not accurate Frequent punctures Possible Cause Remedy • Wheels not aligned in frame • Align wheels correctly • Headset loose or binding • Adjust/tighten headset • Front forks or frame bent • Take bike to a bike shop for possible frame realignment • Inner tube old or faulty • Replace inner tube • Tire tread/casing worn • Replace tire • Tire unsuited to rim • Replace with correct tire • Tire not checked after previous puncture • Remove sharp object embedded in t
7 Warranty ❼ Warranty LIMITED WARRANTY AND POLICY ON REPLACEMENT PROCEDURES & RESPONSIBILITIES Your purchase includes the following warranty which is in lieu of all other express warranties. This warranty is extended only to the initial consumer purchaser. No warranty registration is required. This warranty gives you specific legal rights and you may have other rights which vary from state to state.
Warranty 7 PURCHASE RECORD Fill in immediately and retain as a record of your purchase. Please retain your sales receipt for any possible warranty claims.
